Coded web and associated web handling and working machine

ABSTRACT

An elongated sheet of web material having a longitudinal row of feeding holes in each side edge portion and plurality of binary codes longitudinally spaced along one side edge portion, and a web handling and working machine comprising sprockets which cooperate with said longitudinal rows of feeding holes to feed said web, means for working on said web and means for reading said codes as said web is fed through the machine. Each code comprises a group of data bits and provides such information as the remaining length of web material available to be worked upon, the type of instrument suitable to work on the web, and if a knife blade is suitable, the fact that the instrument should be rotated to maintain it tangent to the line of cut.

BACKGROUND OF THE INVENTION

The invention relates generally to a web and an associated web handlingand working machine which feeds the web longitudinally of itself andworks on the web as it is fed. The invention deals more particularlywith a code on the web which the machine reads as the web is fed, thecode providing such information as the length of the web remaining foruse.

The present invention may be used with any one of various types ofmachines such as a plotting machine, a recording machine or thesignmaking machine described in U.S. Pat. No. 4,467,525 to Logan, issuedon Aug. 28, 1984, assigned to the assignee of the present invention andhereby incorporated by reference as part of the present disclosures. Thesign making machine works on sign making web stock which is stored as aroll and drawn by a pair of feed sprockets having pins which cooperatewith rows of holes in two side edge portions of the web.

Information describing a desired sign pattern such as an alphanumericinscription or a geometric shape is programmed into the machine to causeit to automatically cut the pattern from a continuous length of the web.It is important that enough web remain on the roll to make such apattern before the machine begins to cut it because the machine may notbe equipped to continue cutting a pattern on a fresh roll if theprevious roll is short, in which case the cut portion of the previousroll is wasted. In this machine and others, a machine operator isusually required to estimate, by visually observing the roll, whetherenough web remains to make the desired pattern. However, when little webremains on the roll and the desired pattern is long, the estimation maybe inaccurate.

Furthermore, the signmaking machine described above and other webworking machines may handle a variety of types of webs and may operatewith various types of instruments, and it is important that the properinstrument be utilized for the particular web being fed and that theinstrument be operated in the proper manner. For example, the signmaking machine is often used to plot a sign pattern on a paper webbefore the relatively expensive sign making stock is cut, in which caseit is important that the operator install a plotting tool within themachine and apply the proper weight, if any, needed to develop arequisite stylus pressure.

After an operator is satisfied with the plot of the desired sign, he orshe substitutes signmaking stocl for the paper web and selects asuitable cutting instrument. For most types of signmaking stock, a knifeblade is required in which case it is important that the operatorprogram the signmaking machine to maintain the blade tangent to the lineof cut.

The operator typically relies upon his or her memory, writteninstructions or trial and error to select the proper instrument andstylus pressure weight and, if a cutting blade is required, to programthe machine to maintain the blade tangent to the line of cut. However,errors occur.

Accordingly, a general aim of the invention is to provide a web handlingand working system which reduces errors of the foregoing types.

A more specific aim of the invention is to provide a web handling andworking system including a coded web and a web handling and workingmachine capable of reading the code, which code includes suchinformation as the length of the web remaining on the roll, the type ofinstrument suitable to work on the web, the weight if any required todevelop a suitable stylus pressure, and/or if a knife blade is utilized,the fact that the instrument should be maintained tangent to the line ofcut.

Another specific aim of the present invention is to provide a coded webfor a web handling and working machine of the foregoing type.

Other aims and advantages of the invention will become apparent from thefollowing detailed description of the preferred embodiments and theaccompanying drawings.

SUMMARY OF THE INVENTION

The invention resides in an elongated web and a web handling and workingmachine which feeds the web longitudinally through it. The web includesa code which is readable by the web machine, which code provides suchinformation as the length of web remaining for use, the type or types ofinstruments which are suitable to work on the web, a weight, if any,required to develop a requisite stylus pressure and/or, if a knife bladeis suitable, the fact that the blade should be maintained tangent to theline of cut.

In one aspect of the invention, the web has binary codes spacedperiodically along the length of the web in a side edge portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a web handling and working systemincluding a sign making machine and a web which system embodies thepresent invention. Various portions of the machine and the web arebroken away to reveal additional features.

FIG. 2 is an enlarged scale, fragmentary sectional view of the web takenon the plane 2--2 of FIG. 3.

FIG. 3 is an enlarged scale, fragmentary plan view of the web of FIG. 1.

FIG. 4 is a fragmentary perspective view showing the relationshipbetween the sprockets and the web of FIG. 1 during the loading of theweb.

FIG. 5 is a sectional view taken on the line 5--5 of FIG. 7 of one ofthe sprockets of FIG. 1, an associated bail which is included in themachine of FIG. 1 but omitted from FIG. 1 and an associated set ofoptical scanning elements.

FIG. 6 is a top plan view FIG. 1 which is adjacent the sprocket of FIG.5.

FIG. 7 is a fragmentary, sectional view of the unfragmented machine ofFIG. 1 taken along the line 7--7 of FIG. 1. (Each of the FIGS. 5, 6 and7 shows the sprocket in the same angular orientation.)

FIG. 8 is a flowchart indicating the process by which the web handlingand working machine of FIG. 1 utilizes information obtained from codeson the web.

FIG. 9 is a fragmentary plan view of another web in which the inventionis embodied.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, the invention is there illustrated as embodiedwithin a web handling and working system 8 which includes a sign makingmachine 10 and an associated web 12. The machine 10 is of the type shownand described in more detail in the aforementioned U.S. Pat. No.4,467,525 to Logan, et al. The web has feeding holes (classified belowas driving holes and keying holes) in its side edge portions and ismoved longitudinally of itself, in an illustrated X-coordinatedirection, by a pair of feed sprockets 14,16 which are supported fordriven rotation in unison about a common drive axis 18 and have pins orteeth which engage the holes. A platen or roller 17 located between thetwo sprockets 14 and 16, and similar to that of a typewriter, supports atansverse portion of the web 12 aligned with the sprockets 14, 16 andhas a window 19 through which the web is scanned. The machine 10 furtherincludes two web holddown bails 22 (FIG. 1) and 23 (FIG. 5, 6 and 7) forthe sprockets 14 and 16, respectively, the bail 23 being pivotallymounted to a side portion 21 of the machine 10 and positioned over theportion of the platen 17 which contains the window 19. The bailsnormally hold the web in engagement with the sprockets as the web is fedand, in addition, the bail 23 has an aperture 69 which receives anoptical scanning device discussed in more detail below.

As further illustrated by FIG. 1, the machine 10 also includes a head 24supported on a movable carriage 25 and suitably driven in an illustratedY-coordinate direction relative to the web 12. With the motion of thetool head 24 in the Y-coordinate direction and the feeding of themachine 10 in an illustrated X-coordinate direction, the web is able tocut patterns of most any shape from the web 12. Such cut patterns arelater transferred to a sign base to form a finished sign.

In a normal sign making mode of operation, the tool head 24 is equippedwith a knife-type cutter or blade 26 and the web 12 is an elongatedpiece of sign making stock which, in this case, is opaque. FIG. 2 showssuch sign making stock having an upper layer 80 from which the patternsare cut and a carrier layer 84. The upper layer is typically made ofthermoplastic material such as vinyl on the order of three to five milsthick with an adhesive backing or coating 82 which releasably attachesthe upper layer 80 to the carrier layer 84. The carrier layer consists,for example, of ninety-pound paper coated or impregnated with siliconeto give it the release property.

The machine 10 also is operable in a plotting mode during which a pen,pencil or other plotting tool is placed in the tool head 24 instead ofthe blade 26 and a webbed sheet of paper or the like is fed through themachine. The purpose of plotting mode is to check the accuracy of theinformation entered into the machine before the more expensive signmaking stock is cut. In both the sign making mode and the plotting mode,the machine 10 operates automatically once the web is loaded and thetool is installed to produce the desired plot or pattern as the case maybe. Also, a sensor (not shown) is provided within the tool head to sensethe type of instrument which is installed and to notify the computer ofsuch.

The web 12 is loaded on the sprockets 14 and 16 so that as the web ismoved longitudinally of itself by rotation of the sprockets, linesextending laterally of the web, that is, perpendicular to its sideedges, are parallel to the sprocket axis 18. Typically, the web 12 iswide, for example, nine inches, relative to the spacing between theholes formed in each side edge portion of the web which, for example,are on one-half inch centers. Because of the large width of the webrelative to the spacing of the holes, the web is provided withdistinctive keying holes 54,54 and 56,56 interspersed with driving holes44,44 and 48,48, respectively and the sprockets are provided withdistinctive keying pins 34,34 and 36,36 (FIG. 4) interspersed withdriving pins 30,30 and 32,32, respectively to identify which holes ineach side edge portion of the web should be placed over which pins oneach sprocket to align the web with the sprocket axis.

As indicated by lines 55 and 57, respectively, in FIG. 3 which areperpendicular to side edges 46 and 50 of the web, the keying hold 54indicated as a is laterally aligned with the keying hold 56 indicated asa and the driving hole 44 indicated as a is laterally aligned with thedriving hole 48 indicated as a. To properly load the web 12 onto thesprockets 14 and 16, the sprockets are first turned to a web loadingposition at which position the keying pins face upwardly. Then, the webis positioned over the sprockets such that the keying holes 54,54 arelocated directly above the keying pins 34,34 and the keying holes 56,56are located direction above the keying pins 36,36 as indicated by planeLSTO passing through the sprocket axis 18. Finally, the web 12 islowered onto the sprockets. The holes 44,44 and 54,54 in one side edgeportion of the web are laterally elongated to accommodate the pins 30,30and 34,34 despite variations in web width due to variations intemperature or humidity or manufacture tolerance. For a furtherdescription of such a web, reference may be made to U.S. patentapplication, entitled "Web Loading and Feeding System", filed same dayherewith by Kenneth Wood, David Logan and John LaDue and herebyincorporated by reference as part of the present disclosure.

Focusing now on the present invention as illustrated by FIGS. 3 and 4,the web 12 includes binary codes 60,60. In the illustrated embodiment,the codes take the form of holes punched into the side edge portion ofthe web outboard of the holes 48,48 and 56,56. However, it should beclearly understood that the codes may take other forms such as graphicinscriptions. The codes 60,60 occur periodically along the length of theweb 12 as shown in FIG. 1 and, in the illustrated embodiment, occur onceper set of keying holes 56,56. However, the codes need not occur sooften and may, for example, occur once for every other set of keyingholes.

The codes may also occur at a spacing unrelated to the location orspacing of the keying holes, for example, adjacent every tenth drivinghole in a web having thirteen driving holes per keying hole. Each code60 in the web 12 occurs approximately at a fixed location relative to arespective keying hole 56, the imprecision in code location being due tothe effects of temperature and humidity on the web material and onmanufacture tolerance. Each binary code 60 includes a guard hole 62,binary data bits and a parity bit 66. Each of the data bits takes one oftwo possible forms, a hole 63 representing one binary level or a solid,unpunched portion 65 of the web representing the other binary level.

As shown in FIGS. 5-7, the code 60 is read when it passes over thewindow 19 by an optical scanning system comprising a source of light 71,for example, a continuously illuminated incandescent bulb situatedwithin the platen 17, and a light sensitive element 73, for example, alight sensitive diode (LSD) or a photo conductive element such as Type 9CDS manufactured by Gilway Corporation, situated within the aperture 69in the bail 23. However, it should be noted that there are other ways toread the codes 60,60, for example, by aiming air jets at them andsensing where the air passes through the web or by engaging the codes60,60 with spring loaded fingers whose extended position triggers arespective switch and sensing where the fingers extend through the web.The light source 71 is mounted on a shaft 75 which shaft and lightsource 71 are stationary and which light source is positioned to radiatelight towards the light sensitive element 73. The platen 17 rotatesabout the shaft 75 by means of a bearing 79 and the light passes throughthe window 19 and towards he light sensitive element when the window ispositioned above the light source 71 as is the case in FIGS. 5-7. Themachine 10 also includes a stepping motor (not shown) under the controlof the computer by which the platen is driven, and from its control, thecomputer determines the angular position of the platen 17 and so theangular position of the window 19 and the sprocket 16. Because the codes60,60 occur approximately at fixed locations relative to respectivekeying holes 56,56, and the keying holes 56,56 are engaged by the drivesprocket 16 when the sprocket 16 and the platen are located at knownangular positions, the computer is able to calculate the approximatetime of arrival of each code over the window 19. When the computercalculates that the beginning of code 60 is soon to arrive underneaththe light sensitive element 73, the computer begins to sense the outputof the light sensitive element 73. When the guard hole 62 is situateddirectly underneath the light sensitive element 73, (as is the case ifFIG. 5), the light radiated from the light source 71 passes through thewindow 19 and the guard hole 62 and is received by the light sensitiveelement 73. Hence, the computer learns the precise location of the code60. Another reason that the machine 10 searches for the guard hole 62 isbecause some webs which may be read by the machine 10 do not have a codeadjacent each set of keying holes, and the guard hole informs thecomputer as to the existence of a code to be read.

Because the computer sensed the guard hole 63, it again senses theoutput of the light sensitive element 73 when the sprocket and platenhave been rotated by the stepping motor amount corresponding to thespearation distance between the guard hole 62 and the leading data bite,i.e., when the leading data bit has advanced to a position directlyunderneath the light sensitive element 73. In FIG. 3 this leading databit is shown to be a hole 63i, but depending on the code it could alsobe an unpunched portion 65. Therefore, in the FIG. 3 case, light passesthrough the initial data bit 63i and is sensed by the light sensitiveelement 73 and, in turn, by the computer. This process is repeated foreach data bit 63,65; however, the light sensitive element 73 is nowsensed at intervals corresponding to the separation distance betweendata bits. It should be noted that when a solid data bit 65 appears atthe sensing station, light radiated from the light source 71 is blockedby the opaque web material and does not reach the light sensitiveelement 73 which fact is sensed by the computer also. Finally, thecomputer performs the light sensing process for the parity bit 66 tocheck the validity of the code data bits 63,65.

The number of data bits 63,65 included in each code 60 depends on thetype and amount of information required from it. At least some of thedata bits are commonly used to indicate the length of the web remainingon the roll, and, for example, if the roll of web is 150 feet long andthe keying holes and codes are placed every six inches, then each binarycode 60 requires at least 300 binary levels and, therefore, at leastnine data bits (ten shown in the Figures). For this application, thecodes 60,60 when read in sequence, indicate progressively shorter andshorter lengths of web material available to be worked upon. Forexample, the code 60 indicated as b in FIG. 1 indicates a shorter weblength than the code 60 indicated as a, the web being fed in theillustrated X-direction and the code 60 b being read after the code 60a.

In addition, one or more data bits may be used or binary levels of theoriginal nine data bits which are not needed to indicate the remainingweb length may be delegated to provide the following information: thetype of web material which is currently loaded; the type or types ofinstruments which are suitable to work on the web, for example, a pencilor pen if the web is made of paper or a knife blade if the web is madeof sign-making stock; and if a knife blade is suitable, the fact thatthe blade must be rotated to maintain it tangent to the line of cut.Also, if desired, the code may include bits providing information as tothe proper weight, if any, needed to develop a suitable stylus pressure.

The information provided by each code is or may be displayed on amonitor 90 to instruct an operator how to operate the machine 10 andalso is or may be used directly by the computer 11 to automaticallyoperate the machine 10 in an appropriate manner. The flow chart of FIG.8 illustrates one process for utilizing such information. The computer12 first reads the code 60 and learns the length of the web remainingand the type of tool which is suitable to work on the web. In theillustrated case, the web is signmaking stock and the computer isinformed that a knife blade is suitable. Then, the computer senses thetype of tool which is installed in the tool head 26 by means of thesensor described above and if the tool is not a knife blade, thecomputer displays the problem on the monitor 90 and loops until theproper tool is installed. When the knife blade is installed, thecomputer proceeds to automatically activate the blade rotation motor tomaintain the blade tangent to the line of cut.

At some time, usually after the web 12 is loaded, an operator inputsdata into the computer via a keyboard 92 (FIG. 1) which data defines asign pattern to be cut. From this data, the computer computes, amongother things, the length of web required to produce the pattern. Ifthere is insufficient web material remaining, the computer prevents themachine 10 from cutting the web, sounds an auditory alarm and displaysthe problem on the monitor 90. If there is enough web materialremaining, the computer activates the X-Y motors and an actuator withinthe tool head 26 to cut the sign pattern.

Although not shown in FIG. 8, the code 60 also may include informationas to the weight, if any, required to develop a suitable stylus pressurefor the knife blade. Also, when the operator inputs the pattern data, heor she may also input information defining the type of web material fromwhich the pattern should be cut and the computer can compare thisinformation against that derived from the code 60 to determine if theproper web material has been loaded.

FIG. 9 shows another web 112 embodying the invention, which web has thedriving and keying holes 44,44, 48,48, 54,54 and 56,56 and the code 60hole pattern of the web 12 and is identical to the web 12 except thatthe web 12 is opaque throughout whereas the web 112 is transparent orsemi-transparent throughout a main portion 113 and is striped on a sideedge portion 115 to make the side edge portion 115 opaque. The purposeof the opaque stripe on the web 112 is to block the path of the lightradiated from the light source 71 when the light encounters a solid databit 65 just as the solid portions of the opaque web 12 block the lightradiated from the light source 71. Hence, the web 112 is readable by themachine 10 without modification to the machine.

By the foregoing, web handling and working systems, including coded websand a code reading, web handling and web working machine have beendisclosed. However, numerous modifications and substitutions may be madewithout deviating from the scope of the invention. For example, theshape of the holes in the code 60 may be made rectangular withoutdetracting from the performance of the system.

Also, if desired, a web may be provided with a highly reflective carrierlayer and binary codes inscribed with dark, nonreflective ink on thelower carrier surface of the web on a side edge portion. The inscribedcode includes a guard bit, data bits and a parity bit and provides thesame types of information as the code 60. To read such a code, themachine 10 is slightly modified to include a light sensitive elementsupported adjacent the light source 71 in fixed relation thereto andpositioned to receive light reflected from reflective data bits butshielded from direct exposure to light radiated from the light source71. The computer senses the output of this light sensitive element whenit calculates the arrival of the code into the scanning path of thislight sensitive element. The light sensitive element adjacent the lightsource may be installed in the machine 10 in addition to the lightsensitive element 73 to make the machine versatile enough to read eitherthe punched or inscribed codes, the appropriate light sensitive elementbeing activated by a manually operated switch.

It is also feasible to inscribe the codes with magnetic ink and readthem by magnetically sensing them, or to use holography to readinscribed codes.

It is also possible to substitute a source of pulsing light such a lightemitting diode (LED) for the incandescent light bulb 71. To read thecode using the LED, the computer pulses the LED and senses the output ofthe light sensitive element 73 at times which correspond to the arrivalat the sensing station of the guard hole 62, the data bits 63,65 and theparity bit 66. Because some types of webs exhibit slight variations inthe code location relative to the keying holes 56,56 and therefore,slight variations in location relative to the angular orientation of thesprocket 16, the computer pulses the LED rapidly prior to the arrival ofthe guard bit 62, and when the first such pulse of light reaches thelight sensitive element 73, the computer learns the starting point ofthe code. The computer times subsequent pulses from that point on inrelation ot the angular advancement of the sprocket 16, i.e., at timescorresponding to the calculated arrival of the data bits 63,65 and theparity bit 66 underneath the light sensitive element 73.

It is also possible to feed the web by means of two pairs of pinchingrollers, one pair surrounding each side edge of the web. The rollers ofeach pair engage opposite faces of the web and are rotated in oppositedirections, and thereby feed the web by frictional forces, the webfeeding holes not being needed.

Therefore, the invention has been described by way of illustration andnot limitation.

I claim:
 1. A web for use with a web handling machine having feedingmeans for feeding said web longitudinally of itself, a tool for workingon said web and code reading means for reading a code means on said web,said web comprising:an elongated worksheet having means for cooperatingwith the feeding means of said web handling machine to feed said webthrough said web handling machine, said worksheet also having a workarea for working by said tool extending along the length of saidworksheet and said work sheet in said work area having at least onecharacteristic which may have different values at different pointsspaced a long the length of said worksheet, and code means, integralwith said worksheet, providing a plurality of individual codes eachlocated at a respective one of a plurality of positions spaced from oneanother along the length of said worksheet, each of said codescomprising a plurality of data bits encoded to provide information as tothe value of said at least one characteristic in the vicinity of saidcode and said data bits being readable by said code reading means assaid web is fed through said web handling machine by said feeding meansof said web handling machine. said worksheet having two side edgeportions extending along the length thereof and between which said workarea is located. said means for cooperating with the web feeding meansof said web handling machine comprising a first row of holes in one ofsaid side edge portions of said worksheet and a second row of holes inthe other of said side edge portions of said worksheet, the holes ofboth of said rows being spaced from one another by a constant spacingalong the length of said worksheet, the holes of each of said rowsincluding a plurality of feed holes and a lesser plurality of keyingholes, said keying holes being spaced regularly from one another alongthe length of said worksheet and there being a constant number of saidfeed holes appearing between each adjacent pair of said keying holes,each of said keying holes having associated with it a characteristicmaking it visually distinguishable from said feed holes, said keyingholes of one of said rows appearing at the same positions along thelength of said worksheet as the keying holes of the other of said rows,and said codes being located at positions spaced from one another alongthe length of said worksheet by the same spacing as appears between saidkeying holes of each of said rows of holes.
 2. A web for use with a webhandling machine having feeding means for feeding said weblongitudinally of itself, a tool for working on said web and codereading means for reading a code means on said web, said webcomprising:an elongated worksheet having means for cooperating with thefeeding means of said web handling machine to feed said web through saidweb handling machine. said worksheet also having a work area for workingby said tool extending along the length of said worksheet and saidworksheet in said work area having at least one characteristic which mayhave different values at different points spaced along the length ofsaid worksheet, and code means, integral with said worksheet, providinga plurality of individual codes each located at a respective one of aplurality of positions spaced from one another along the length of saidworksheet, each of said codes comprising a plurality of data bitsencoded to provide information as to the value of said at least onecharacteristic in the vicinity of said code and said data bits beingreadable by said code reading means as said web is fed through said webhandling machine by said feeding means of said web handling machine.said worksheet having two side edge portions extending along the lengththereof and between which said work area is located, said means forcooperating with the web feeding means of said web handling machinecomprising a first row of holes in one of said side edge portions ofsaid worksheet and a second row of holes in the other of said side edgeportions of said worksheet, the holes of both of said rows being spacedfrom one another by a constant spacing along the length of saidworksheet, the holes of each of said rows including a plurality of feedholes and a lesser plurality of keying holes, said keying holes beingspaced regularly from one another along the length of said worksheet andthere being a constant number of said feed holes appearing betweenadjacent pairs of said keying holes, each of said keying holes havingassociated with it a characteristic making it visually distinguishablefrom said keying holes, said keying holes of one of said rows appearingat the same positions along the length of said worksheet as the keyingholes of the other of said rows, and said codes being located atapproximately the same positions along the length of said web as saidkeying holes.